The assembly, testing, and packaging production line for domestic air conditioner indoor and outdoor units is highly automated and efficient. It includes detailed processes like component processing, cleaning, coating, core component assembly, vacuum extraction, refrigerant injection, comprehensive performance testing, and precise quality control. The layout is optimized for both indoor and outdoor unit production, with advanced logistics systems for smooth material flow. This line ensures high production efficiency, achieving significant daily outputs for both units. Supported by a robust quality control system adhering to ISO 9001 standards, it guarantees high product quality with a non-conforming rate of less than 0.5%. Innovative features such as intelligent inspection and a flexible production model further enhance its capabilities, making it a state-of-the-art facility in the industry.

A small-scale domestic air conditioner assembly production line

I. Assembly Line for Indoor Units

(1) Processing and Pre-treatment of Components

A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly production line
  1. Plastic Component Molding and Machining
  • Equipment: Automatic Injection Molding Machine (Model: XX-1000T, Clamping Force: 1000 tons, Injection Speed: 50–200 mm/s)
  • Process: The injection molding machine heats and melts plastic pellets, then injects them into molds to form components such as the indoor unit’s casing and air ducts. After the components are ejected by robotic arms, they undergo surface treatment processes like deburring and polishing.
  • Technical Parameters: Molding cycle: approximately 30–60 seconds per piece, Molding accuracy: ±0.1 mm.
  1. Metal Component Machining
  • Equipment: CNC Punch Press (Model: CNC-2000, Punching Force: 2000 kN, Punching Speed: 500 cycles/min), CNC Bending Machine (Model: Bend-1500, Bending Force: 1500 kN)
  • Process: Metal sheets are punched and bent to form components such as the indoor unit’s frame and panel. The processed components are then treated for rust removal and rust prevention.
  • Technical Parameters: Punching accuracy: ±0.2 mm, Bending angle accuracy: ±0.5°.

(2) Cleaning and Coating of Components

  1. Cleaning
  • Equipment: Automatic Ultrasonic Cleaning Line (Model: Ultrasonic-50, Cleaning Tank Dimensions: 5000 mm × 1000 mm × 800 mm)
  • Process: Metal and plastic components are placed into the cleaning tank. The high-frequency vibrations of the ultrasonic waves, combined with the chemical action of the cleaning solution, remove oil, dust, and other impurities from the component surfaces.
  • Technical Parameters: Cleaning temperature: 50–60°C, Cleaning time: 10–15 minutes, Surface cleanliness of cleaned components: ISO Class 8.
  1. Coating
  • Equipment: Automatic Coating Robot (Model: SprayBot-6, Coating Range Radius: 6 meters, Coating Speed: 1000–2000 mm/s)
  • Process: The robot applies coating to the components according to preset coating paths and parameters. The coating material used is an environmentally friendly powder coating. The coating is applied through electrostatic adhesion and high-temperature curing processes to form a robust and aesthetically pleasing coating.
  • Technical Parameters: Coating thickness: 50–80 μm, Adhesion strength: ≥5 MPa, Corrosion resistance (salt spray test): ≥500 hours.

(3) Assembly of Indoor Units

  1. Core Component Assembly
  • Equipment: Automatic Assembly Robot (Model: AssemBot-300, Payload: 300 kg, Repeatability Accuracy: ±0.05 mm)
  • Process: The robot successively assembles core components such as the compressor and evaporator onto the indoor unit’s base. High-precision positioning fixtures and torque-controlled tools are used to ensure that the components are properly installed and securely connected.
  • Technical Parameters: Compressor installation accuracy: ±0.5 mm, Evaporator installation angle accuracy: ±1°.
  1. Pipeline and Wiring Connection
  • Equipment: Automatic Welding Robot (Model: WeldBot-200, Welding Current: 200 A, Welding Speed: 200–500 mm/min), Automatic Wiring Equipment (Model: WireLay-10, Wiring Speed: 10 m/min)
  • Process: The welding robot automatically welds the refrigerant pipelines. During the welding process, a protective gas is used to ensure welding quality. The wiring equipment arranges and secures power cables and signal wires according to preset paths.
  • Technical Parameters: Welding joint strength: ≥200 MPa, Wiring neatness error: ≤2 mm.
  1. Control Panel Installation
  • Equipment: Automatic Installation Equipment (Model: PanelMount-50, Installation Speed: 50 seconds per piece)
  • Process: The electronic control panel is installed onto the indoor unit’s casing. An automated screw-tightening device ensures that the panel is securely installed and the electrical connections are reliable.
  • Technical Parameters: Panel installation position accuracy: ±1 mm, Screw-tightening torque accuracy: ±5%.

(4) Vacuum Extraction and Refrigerant Injection

  1. Vacuum Extraction
  • Equipment: Automatic Vacuum Pump (Model: VacPump-100, Vacuum Extraction Rate: 100 L/s, Ultimate Vacuum: 1×10⁻³ Pa)
  • Process: The vacuum pump is connected to the refrigeration system of the indoor unit via pipelines. After activation, it extracts air from the system to ensure that no air remains inside, creating conditions for refrigerant injection.
  • Technical Parameters: Vacuum extraction time: ≤10 minutes, System vacuum level: 1×10⁻³ Pa.
  1. Refrigerant Injection
  • Equipment: Automatic Refrigerant Injection Machine (Model: Refill-500, Injection Accuracy: ±0.5 g)
  • Process: Based on the model and specifications of the indoor unit, the appropriate amount of refrigerant is automatically injected. During the injection process, the pressure and flow rate of the refrigerant are monitored in real-time to ensure accurate injection volume.
  • Technical Parameters: Injection time: ≤5 minutes, Refrigerant injection volume accuracy: ±0.5 g.

(5) Performance Testing

  1. Cooling and Heating Performance Testing
  • Equipment: Automatic Test Bench (Model: TestBench-1000, Test Temperature Range: -20°C to 50°C, Test Air Speed Range: 0.5–5 m/s)
  • Process: The assembled indoor unit is placed on the test bench. Different indoor and outdoor environmental conditions are simulated. Data on cooling and heating effects and energy efficiency ratios are collected through sensors to determine whether the product meets design requirements.
  • Technical Parameters: Test accuracy: ±0.5°C, Test time: ≤30 minutes.
  1. Electrical Performance Testing
  • Equipment: Automatic Electrical Testing Equipment (Model: ElecTest-200, Test Voltage Range: 0–250 V, Test Current Range: 0–50 A)
  • Process: Electrical performance tests are conducted on the indoor unit’s power cord and control circuits, including insulation resistance, leakage current, grounding resistance, and other items, to ensure the product’s electrical safety.
  • Technical Parameters: Insulation resistance: ≥2 MΩ, Leakage current: ≤0.5 mA.

(6) Commercial Inspection (Quality Control)

  1. Appearance Inspection
  • Equipment: Automatic Vision Inspection System (Model: VisionCheck-50, Inspection Accuracy: 0.1 mm, Inspection Speed: 50 pieces per minute)
  • Process: High-resolution cameras scan the entire surface of the indoor unit to detect surface defects such as scratches, deformations, and coating flaws. The system automatically identifies and marks不合格products.
  • Technical Parameters: Inspection accuracy: 0.1 mm, Inspection coverage: over 95% of the product surface.
  1. Performance Re-inspection
  • Equipment: Automatic Performance Re-inspection Equipment (Model: ReTest-300, Re-inspection Time: ≤10 minutes)
  • Process: Products that have passed the initial performance test are randomly selected for re-inspection, focusing on key indicators such as cooling and heating effects and energy efficiency ratios, to ensure the consistency and stability of product quality.
  • Technical Parameters: Re-inspection ratio: 10%, Re-inspection accuracy: same as the initial test.

(7) Quality Inspection

  1. Comprehensive Inspection
  • Equipment: Automatic Comprehensive Inspection Station (Model: ComTest-800, Number of Inspection Items: 30, Inspection Time: ≤20 minutes)
  • Process: A comprehensive quality inspection is conducted on the indoor unit, covering multiple aspects such as appearance, performance, and electrical safety. Inspection results are automatically recorded and uploaded to the quality management system.
  • Technical Parameters: Inspection item coverage rate: 100%, Inspection result accuracy: ≥99%.
  1. Sampling Inspection
  • Equipment: Automatic Sampling Inspection Equipment (Model: SampleTest-200, Sampling Frequency: 1 time per hour)
  • Process: Products on the production line are randomly sampled at a certain frequency. The sampled products are subjected to stricter inspections, including destructive testing, to ensure the reliability of product quality.
  • Technical Parameters: Sampling frequency: 1 time per hour, Number of sampling inspection items: 50.

(8) Packaging

  1. Packaging Material Assembly
  • Equipment: Automatic Packaging Robot (Model: PackBot-150, Payload: 150 kg, Packaging Speed: 15 pieces per hour)
  • Process: The robot successively assembles packaging materials such as plastic bags, foam cushioning, and cardboard boxes onto the indoor unit, ensuring the correct installation and fixation of the packaging materials.
  • Technical Parameters: Packaging accuracy: ±2 mm, Packaging speed: 15 pieces per hour.
  1. Box Sealing
  • Equipment: Automatic Box Sealing Machine (Model: SealBox-100, Sealing Speed: 100 pieces per hour)
  • Process: The box sealing machine seals the packaged indoor unit. An automated tape cutting and adhering device ensures that the box is securely sealed and the appearance is neat.
  • Technical Parameters: Sealing accuracy: ±1 mm, Sealing speed: 100 pieces per hour.
  1. Labeling and Scanning
  • Equipment: Automatic Labeling Machine (Model: LabelApp-50, Labeling Speed: 50 pieces per hour), Automatic Scanning Equipment (Model: ScanCode-100, Scanning Speed: 100 pieces per hour)
  • Process: The labeling machine automatically applies product labels to the cardboard boxes. The labels contain information such as product model, specifications, and production date. The scanning equipment scans the labels and records the product information into the logistics management system.
  • Technical Parameters: Labeling accuracy: ±1 mm, Scanning accuracy rate: ≥99.9%.

II. Assembly Line for Outdoor Units

(1) Processing and Pre-treatment of Components

  1. Plastic Component Molding and Machining
  • Equipment: Automatic Injection Molding Machine (Model: XX-1500T, Clamping Force: 1500 tons, Injection Speed: 50–200 mm/s)
  • Process: Components such as the outdoor unit’s casing and air ducts are formed. After molding, the components undergo surface treatment.
  • Technical Parameters: Molding cycle: approximately 40–70 seconds per piece, Molding accuracy: ±0.1 mm.
  1. Metal Component Machining
  • Equipment: CNC Punch Press (Model: CNC-3000, Punching Force: 3000 kN, Punching Speed: 500 cycles/min), CNC Bending Machine (Model: Bend-2000, Bending Force: 2000 kN)
  • Process: Metal components such as the outdoor unit’s frame and panel are processed.
  • Technical Parameters: Punching accuracy: ±0.2 mm, Bending angle accuracy: ±0.5°.

(2) Cleaning and Coating of Components

  1. Cleaning
  • Equipment: Automatic Ultrasonic Cleaning Line (Model: Ultrasonic-60, Cleaning Tank Dimensions: 6000 mm × 1200 mm × 1000 mm)
  • Process: Metal and plastic components are cleaned.
  • Technical Parameters: Cleaning temperature: 55–65°C, Cleaning time: 12–18 minutes, Surface cleanliness of cleaned components: ISO Class 8.
  1. Coating
  • Equipment: Automatic Coating Robot (Model: SprayBot-8, Coating Range Radius: 8 meters, Coating Speed: 1000–2000 mm/s)
  • Process: Components are coated.
  • Technical Parameters: Coating thickness: 60–100 μm, Adhesion strength: ≥5 MPa, Corrosion resistance (salt spray test): ≥500 hours.

(3) Assembly of Outdoor Units

  1. Core Component Assembly
  • Equipment: Automatic Assembly Robot (Model: AssemBot-500, Payload: 500 kg, Repeatability Accuracy: ±0.05 mm)
  • Process: Components such as the compressor and condenser are assembled.
  • Technical Parameters: Compressor installation accuracy: ±0.5 mm, Condenser installation angle accuracy: ±1°.
  1. Pipeline and Wiring Connection
  • Equipment: Automatic Welding Robot (Model: WeldBot-300, Welding Current: 300 A, Welding Speed: 200–500 mm/min), Automatic Wiring Equipment (Model: WireLay-20, Wiring Speed: 20 m/min)
  • Process: Refrigerant pipelines are welded, and wires are arranged.
  • Technical Parameters: Welding joint strength: ≥200 MPa, Wiring neatness error: ≤2 mm.
  1. Motor and Fan Blade Assembly
  • Equipment: Automatic Assembly Equipment (Model: MotorMount-100, Assembly Speed: 100 seconds per piece)
  • Process: Motors and fan blades are installed.
  • Technical Parameters: Motor installation position accuracy: ±1 mm, Fan blade installation angle accuracy: ±0.5°.

(4) Vacuum Extraction and Refrigerant Injection

  1. Vacuum Extraction
  • Equipment: Automatic Vacuum Pump (Model: VacPump-200, Vacuum Extraction Rate: 200 L/s, Ultimate Vacuum: 1×10⁻³ Pa)
  • Process: The refrigeration system is evacuated.
  • Technical Parameters: Vacuum extraction time: ≤12 minutes, System vacuum level: 1×10⁻³ Pa.
  1. Refrigerant Injection
  • Equipment: Automatic Refrigerant Injection Machine (Model: Refill-1000, Injection Accuracy: ±0.5 g)
  • Process: Refrigerant is injected.
  • Technical Parameters: Injection time: ≤8 minutes, Refrigerant injection volume accuracy: ±0.5 g.

(5) Performance Testing

  1. Cooling and Heating Performance Testing
  • Equipment: Automatic Test Bench (Model: TestBench-2000, Test Temperature Range: -20°C to 50°C, Test Air Speed Range: 0.5–5 m/s)
  • Process: Cooling and heating effects are tested.
  • Technical Parameters: Test accuracy: ±0.5°C, Test time: ≤40 minutes.
  1. Electrical Performance Testing
  • Equipment: Automatic Electrical Testing Equipment (Model: ElecTest-300, Test Voltage Range: 0–250 V, Test Current Range: 0–50 A)
  • Process: Electrical performance is tested.
  • Technical Parameters: Insulation resistance: ≥2 MΩ, Leakage current: ≤0.5 mA.

(6) Commercial Inspection (Quality Control)

  1. Appearance Inspection
  • Equipment: Automatic Vision Inspection System (Model: VisionCheck-80, Inspection Accuracy: 0.1 mm, Inspection Speed: 80 pieces per minute)
  • Process: Appearance is inspected.
  • Technical Parameters: Inspection accuracy: 0.1 mm, Inspection coverage: over 95% of the product surface.
  1. Performance Re-inspection
  • Equipment: Automatic Performance Re-inspection Equipment (Model: ReTest-500, Re-inspection Time: ≤15 minutes)
  • Process: Performance is re-inspected.
  • Technical Parameters: Re-inspection ratio: 10%, Re-inspection accuracy: same as the initial test.

(7) Quality Inspection

  1. Comprehensive Inspection
  • Equipment: Automatic Comprehensive Inspection Station (Model: ComTest-1200, Number of Inspection Items: 35, Inspection Time: ≤25 minutes)
  • Process: Comprehensive quality inspection is conducted.
  • Technical Parameters: Inspection item coverage rate: 100%, Inspection result accuracy: ≥99%.
  1. Sampling Inspection
  • Equipment: Automatic Sampling Inspection Equipment (Model: SampleTest-300, Sampling Frequency: 1 time per hour)
  • Process: Sampling inspection is conducted.
  • Technical Parameters: Sampling frequency: 1 time per hour, Number of sampling inspection items: 50.

(8) Packaging

  1. Packaging Material Assembly
  • Equipment: Automatic Packaging Robot (Model: PackBot-200, Payload: 200 kg, Packaging Speed: 20 pieces per hour)
  • Process: Packaging materials are assembled.
  • Technical Parameters: Packaging accuracy: ±2 mm, Packaging speed: 20 pieces per hour.
  1. Box Sealing
  • Equipment: Automatic Box Sealing Machine (Model: SealBox-150, Sealing Speed: 150 pieces per hour)
  • Process: Box sealing is performed.
  • Technical Parameters: Sealing accuracy: ±1 mm, Sealing speed: 150 pieces per hour.
  1. Labeling and Scanning
  • Equipment: Automatic Labeling Machine (Model: LabelApp-100, Labeling Speed: 100 pieces per hour), Automatic Scanning Equipment (Model: ScanCode-200, Scanning Speed: 200 pieces per hour)
  • Process: Labeling and scanning are performed.
  • Technical Parameters: Labeling accuracy: ±1 mm, Scanning accuracy rate: ≥99.9%.

III. Overall Layout of the Production Line and Logistics System

(1) Layout of the Production Line

  1. Indoor Unit Production Line
  • Length: Approximately 200 meters
  • Width: 15 meters
  • Number of Workstations: 50
  • Personnel Allocation: 50 people (30 operators, 10 technicians, 10 quality inspectors)
  1. Outdoor Unit Production Line
  • Length: Approximately 250 meters
  • Width: 18 meters
  • Number of Workstations: 60
  • Personnel Allocation: 60 people (35 operators, 12 technicians, 13 quality inspectors)

(2) Logistics System

  1. Automatic Conveying Line
  • Equipment: Automatic Conveyor Belt (Model: Conveyor-5000, Conveying Speed: 50–100 m/min)
  • Function: Conveys the assembled indoor and outdoor units to the packaging and testing areas, achieving seamless connections between production stages.
  • Technical Parameters: Conveying accuracy: ±1 mm, Conveying capacity: 500 pieces per hour.
  1. Storage and Logistics
  • Equipment: Automatic立体Warehouse (Model: Warehouse-1000, Storage Capacity: 10,000 pieces), Automatic Forklift (Model: ForkLift-5000, Payload: 5000 kg)
  • Function: Stores finished air conditioners, and transports products to the logistics shipping area via automated forklifts.
  • Technical Parameters: Space utilization rate of the warehouse: ≥80%, Forklift operating speed: 10 km/h.

IV. Production Efficiency and Quality Control

(1) Production Efficiency

  1. Indoor Unit Production Efficiency
  • Single-shift Output: 1000 units per day
  • Double-shift Output: 2000 units per day
  1. Outdoor Unit Production Efficiency
  • Single-shift Output: 800 units per day
  • Double-shift Output: 1600 units per day

(2) Quality Control

  1. Quality Control System
  • Standard: ISO 9001 Quality Management System
  • Inspection Coverage: 100%
  • Non-conforming Product Rate: ≤0.5%
  1. Quality Traceability System
  • Function: Through product labels and QR codes, the entire process from raw materials to finished products can be traced to quickly locate and resolve quality issues.
  • Technical Parameters: Traceability time: ≤10 minutes, Traceability accuracy rate: 100%.

V. Technical Advantages and Innovation Points

  1. High Degree of Automation: The production line uses a large number of automated devices to reduce human intervention and improve production efficiency and product quality.
  2. Intelligent Inspection: Automated inspection equipment can collect data in real-time. Big data analysis is used to optimize production processes.
  3. Green and Environmentally Friendly: Environmentally friendly coating materials and energy-saving equipment are used to reduce energy consumption and environmental pollution during the production process.
  4. Flexible Production: The production line can quickly adjust product models and output volumes according to market demand, adapting to a production model with multiple varieties and small batches.